07/30/2024 Posted By Siarhei Kanushok

Introduction

Installing a pre-hung exterior door may seem intimidating, but with proper guidance, the right tools, and patience, you can manage it yourself. The process requires accuracy and focus to ensure the door operates smoothly, providing security and insulation. This guide explains each step, highlighting challenges like uneven frames and misalignment. Whether updating an old door or adding a new one, this resource will help you achieve a successful installation. The task is moderately challenging and takes about 4-6 hours.

Because steel front doors are significantly heavier than wooden interior doors, it is safest to install them with two people.

Planning and preparation

Choosing the right exterior door

For DIY enthusiasts, pre-hung exterior doors are a transformative option. Instead of struggling with separate frames, hinges, and alignment issues, you receive a door expertly fitted into its frame—ready for straightforward installation. Choosing the right exterior door is crucial for security, insulation, and curb appeal. Here are some key factors to consider:

  • Material: Wooden exterior doors may appear luxurious, but they require extensive maintenance due to their susceptibility to external factors. Steel models and fiberglass doors are the most reliable and energy-efficient.
  • Insulation: Select doors with good insulation properties. A well-insulated door will help reduce energy costs and keep your home comfortable.
  • Security: Ensure the door has robust features, such as a zinc-galvanized steel slab, reinforced frame, and high-quality hardware.
  • Style and design: The door should complement your home's architectural style. Consider the color, finish, and any decorative elements.
  • Size: Measure your rough opening accurately and choose a door that fits well.
  • Budget: Determine your budget and find a door that offers the best features and quality within your price range.

Tools needed

Before starting, make sure you have all the necessary tools:

  • Power drill: for drilling holes and driving screws.
  • Tape measure: for precise measurement of doors and frames.
  • Chisel: for cutting and adjusting as needed.
  • Self-centering hinge drills: for creating precisely centered pilot holes for screws.
  • Level: it ensures your door is perfectly level and plumb, which is crucial for smooth operation.
  • Wood shims: for adjusting the door to the correct position.
  • Hammer: for making recesses for hinges and strike plates, and driving finishing nails for casing and shims.
  • Safety glasses: for protecting your eyes.
  • Pencil: for marking measurements and outlines.
  • Screws: for securing door unit components (the length of the screws for installation must be selected depending on the type of wall).
  • Mounting foam: for securing the door frame.
  • Knife: for the removal of mounting foam.

If you lack any tools, visit a hardware store, because good preparation makes installation smoother and faster.

Please ensure the kit is complete after purchasing or delivering the exterior door:

  • Door frame: header, hinge jamb, strike plate jamb, and threshold.
  • Slab (already pre-drilled for hinges and handle).
  • Transom and sidelites (optional).

Step 1: Remove the old door unit

If there is a front door in your doorway, open it, unscrew the hinges, and remove the slab. Then, proceed to dismantle the casings and door frame by cutting the mounting foam.

Step 2: Prepare the rough opening

After removing the old exterior door, you need to clean the rough opening. Remove any remaining debris: construction foam, fasteners, and dust.

Step 3: Check the sizes

Ensure that the door size matches the dimensions of the rough opening. Before purchasing a front door, we recommend reading the step-by-step instructions on how to determine the required height and width of the slab.

Step 4: Door frame assembly and fixing it in the rough opening

You can now start installing the exterior door. Assemble the door frame by fastening all parts together with screws. Apply mounting foam around the perimeter (joint width is 4”-6”), filling it with foam that has an expansion of ≤ 20% (ASTM C1620). Attach all jambs to the door opening, taking into account your chosen swing direction. Check the horizontal position of the threshold and the vertical position of the jambs using a level to ensure the door frame is not distorted.

Step 5: Installation of hinges

Before fastening the screws, drill holes in the slab using a drill bit that is smaller in diameter than the screws. Do not install the hinge caps at this stage.

Step 6: Hanging the slab on the door frame and hinge adjustment

Hang the slab on the frame (two people are required) and adjust the hinges using the Allen wrench. The gap between the slab and the door frame should be 1/8". Secure hinges to the door jamb with the screws.

Step 7: Door alignment

Close the door and align the header and jambs around the slab. Keep nice-looking gaps between the slab and frame.

Step 8: Transom and sidelites installation

Connect the transom to the frame with the screws through the technological holes in the frame. Install a casing between the frame and the transom. Secure 0,7” steel angles (at least 4 pieces) and fix anchor bolts to the wall opening. The distance between the fastening corners is no more than 4,7”.

Step 9: Hardware installation

For door handle installation and lock drilling, please refer to the lock manufacturer's instructions, because each type of hardware has its own characteristics. Finally, check that the door and all its components are working correctly.

Conclusion

Installing an exterior door is a manageable project for a DIY enthusiast with the right tools and a bit of patience. By following this comprehensive guide, you can confidently replace or install your exterior door, enhancing your home's security and aesthetic appeal. However, if you feel unsure at any point, consulting a professional can save time, prevent errors, and extend the life of your new door. Professionals have the experience and tools to handle any installation challenges, ensuring a high-quality result.

FAQ

How long does it take to install an exterior door?

It takes about 4-6 hours.


Can I install an exterior door myself?

Yes. We recommend reading our article and the manufacturer's instructions.

What is the most common mistake when installing an exterior door?

TOP-5 most common critical mistakes:

  • Inaccurate measurements. To determine the correct door size, please follow our detailed instructions.

  • Ignoring the alignment check steps. Be sure to use a level to ensure that the door is installed evenly and will last for many years.

  • Unsuitable screws. Please note that their length depends on the type of wall.

  • Poor sealing. If there are gaps after installation, the door will allow outside noise, cold, dust, and possibly small insects to enter.

  • No final check. Ensure that your door opens and closes smoothly.